Polaris Sportsman 400 Service Manual page 240

FINAL DRIVE
MAGNETIC COIL REMOVAL
1. Remove the front drive axle as described later
in this chapter.
2. Remove the seal sleeve from the strut casting
using a drift punch and hammer, tapping
evenly on each side until the sleeve slides off.
3. Remove the existing coil and clean the coil
wire channel, coil mount area, and the seal
sleeve mounting area of all silicone and
foreign matter.
4. Disconnect the coil wires at the connector or
terminal board.
MAGNETIC COIL INSTALLATION
1. Apply 1/4I (.6 cm) bead of silicone in the coil
wire channel.
2. Install the coil to the coil mount surface and
press the coil wires into the silicone in the coil
wire channel.
3. Apply 1/4I (.6 cm) bead of Loctite™ Ultra Blue
silicone around the seal sleeve mounting area.
NOTE: This includes applying silicone over
the coil lead wires again. Always allow 12
hours' cure time for silicone.
4. Press on the seal sleeve until even with the
inner pole. See page 7.17 for additional
information. Once the seal sleeve is properly
positioned, a 1/16I (.16 cm) bead of silicone
should remain around the inner edge. Clean
off all excess silicone. The seal sleeve area
must be free of silicone or the hub seal may
leak.
NOTE:
- Always install a new seal sleeve when
replacing the coil. Use tool PN 2871199.
- It may be necessary to apply more silicone
(or an equivalent fast drying glue) to the
wire channel area to properly secure and
protect the coil wires.
5. Apply 401 Loctitet to the inside of the strut
ribs and press the foam block to contain the
coil wires. Make sure the foam block is
bonded well to protect the coil wires.
NOTE: Coil wires must be contained in the brake
line clip on the back side of the upper strut casting
and the wires must be snug against the casting.
6. Route the wires smoothly and away from any
moving parts and secure in place with tie
straps.
7. Assemble front axle and connect hub wires.
7.8
- projex@inbox.lv -
Strut Ribs
Coil Wire
Channel
Seal Sleeve
Mounting
Area
Coil Mounting
Surface
(Inner Magnet Pole)
(Fixed)
Electromagnet Coil
Seal Sleeve (Outer Magnet Pole)
(Adjustable) Must use tool PN 2871199
Brake Line
Clip Location